Art of casting ingot molds and apparatus for same



I 1,620,128 PIarch 8, 1927- J P RRY ART OF CASTING INGOT MOLDS AND APPARATUS FOR SAME Filed May l4, 1924 3 Sheets-Sheet 1 INVENTOR (fa/272 E Per/y M ATTORNEY J. E. PERRY ART OF CASTING INGOT MOLDS AND APPARATUS FDR SAME arch 8,

Filed May 14. 1924 3 Sheets-Sheet 2 ATTORNEY J. E. PERRY ART OF CASTING INGOT MOLDS AND APPARATUS FOR SAME March 8, 1927.

Filed May 14, 1924 3 Sheets-Sheet 5 ATTORNEY Patented Mar. 8, i927.

umrco STATES PATENT OFF-ICE.

JOHN E. PERRY, OF SHARON, PENNSYLVANIA, ASSIGNOR TO VALLEY MOULD & IRON GORPORATION,-OF SHARPSVILLE, PENNSYLVANIA, A. CORBORATION OF NEW YORK.

' ART or CASTING rneor aromas AND APPARATUS ronsemn.

Application filed May 14,

vThis invention relates broadly to metallurgy and more specifically to the art and apparatus for casting ingot molds.

The procedure for casting-ingot molds which is common in the art comprises setting up an iron flask and clamping the parts together. The flask may have a thin metal stripping plate temporarily'attached to the bottom thereof. The pattern for the mold is usually set up on the ramming floor and the flask is set over the pattern; then manipulated by a workman, relying entirely upon skill, to center the flask over the pattern without the use of definite centering devices. The space between the flask and the pattern is rammed with mold sand. WVhen the ramming is completed a crane lifts the flask with the sand therein from the pattern and the temporary strip-ping plate is removed. Workmen then proceed to cut the sand even with the bottom of the flask, prov ded there has been any springing of the flask away from the stripping plate as is usually the case, and also cut a gate opening to form a channel for molten metal. The mold is then placed on a rack for drying. During these operations the sand is'very frequently broken and requires patching'. If the flask is accidentally jarred, such part of the rammed sand may fall away as to ruin the sand mold and require re-ramming. It will be recognized that in view of the very large size which ingot molds frequently assume, that the sand mold for casting ingot molds is a large affairand in swinging it with the crane a very' small jar may cause considerable damage. lVhere molds are patched, the patchingsand is of different temper from the main ,san d, thereby frequently introduces flaws into the finished casting. I 1 i The core for the ingot mold heretofore has usually comprised a core bar forming the support or frame Work to support a sand facing, and around which core bar mold sand is rammed by setting the core bar in a ramming box. Then the ramming box, is stripped from the core bar, the sanded core is blacked and dried. When the core is ready for use it is set up on a casting plate or bottom in such mannerias to be capable for adjustment, then the flask with the sand therein ,is handled by a crane'and set down over the core bar onto the casting plate. The workman relies upon his eye and skill tocentralize the core bar so that the upper end is. as

1924. Serial No. 713,123.

near in the center of the flask as possible for the workman to determine. The position of the flask is then marked on the casting plate, and the flask islifted from the plate so that sand may be packed around the bottom of the core bar to hold the bar vertical and to prevent metal from forming fins amder the bar. The flask is again picked up and replaced over the core bar on the casting a and the liabilities of injury to the sanded flask or core bar are increased by the excess number of operations. which must be performed. Furthermore, ,since the set-up is done by skill rather than by interfitting of parts, it will be obvious that it is impossible to set the parts in exactly the same position each time and therefore there will be as many different variations in the finished product as there are individual setsups made. Careless work will result in-defective molds which cannot be sold, and a few rejections means a great deal in View of the extremely large size of the castings comprising ingot molds. The usual number of men required for setting up operations as heretofore practiced in the art is about sixteen men for each set-up. v x The present invention greatly sim lifies the procedure and also provides inte tting parts which eliminate the element of chance or skill and enables the operations to be carried on with certainty and with less skilled labor.

In carrying out the present invention the flask is made of cast iron and is provided with permanent heavy metal stripping plates securely attached to bottoms of the sections of the flask. These stripping plates are rovided with cut outs which when assem led form an opening that fits the bottom of a cast iron mold pattern, which is also securely attachedto a metal ramming plate orbase. The base flange of the flask and also the ramming plate on the mold pattern are pro-- pered ended setting pins so that when the flask is set over the metal pattern and the setting pins are-inserted through the flask flange and the ramming base, the parts will be accurately and firmly set with the pattern exactly and definitely positioned within the flask. The sections of the flask are fastened together with C-clamps so that mold sand may be tightly and securely rammed between the pattern and the flask without danger of disturbing the parts. When the flask is stripped from the pattern the heax'y permanent stripping plates of the base of the flask carry and support the mold sand so that the danger of breaking is obviated. After the flask is stripped from the pattern the gate is cut and the flask is blackened and dried. It will be noted that this manipulation requires but a single operation. and does not require lowering the flask to release stripping plate or cutting the sand even with the bottom, etc., as in the prior practice.

The core bar in carrying out the present invention is provided with a relatively large wide base which is fixedly and rigidly secured to the core bar standard. This base has a sufiicient width to extend beneath the matrix in the mold set-up and also to extend out under the bottom portion of the flask. This core bar base is provided with upstanding portions adjacent its outer edge which are adapted to contact with the heavy stripping plates or bottom of the flask, so that the flask sets partly on the casting bottom and partly over the base of the core bar, and the core bar base sets in an opening in the casting bottom that is exactly centered relative to the casting bottom. When the core bar is ready for ramming a layer of sand is arranged over a dish-shaped portion of the core bar base. This base of the core bar exactly fits into a ramming base on the core bar box. The sides of the core bar box are cast iron doors or sides which are hinged to the ramming base like a pair of gates and close over the base of the core bar to rest upon the upstanding edge of this base, thereby accurately positioning and locking the core bar vertically in the ramming box to securely maintain the parts in this position during the ramming operation. The edges of the sides of the box smooth down the sand which was jammed in the dish-shaped portion of the core bar base. Mold sand is now rammed around the sides of the core bar column, which may be of the well-known collapsible type. After the ramming operation is completed the core bar box is opened and the core bar is lifted by a crane and set aside to dry, after first being blackened. It will be observed that the large heavy base on the core bar provides a complete support for the bottom portion of the sand packed around the core bar. After the core bar is dried it is picked up by a crane and set into an open-- me ias bar base and the casting bottom to fill these intermediate spaces. The sanded flask is now set down over the core bar and upon the casting bottom, where it is accurately positioned by the setting pins which go through the openings in the base flange of the flask and similar openings in thecasting bottom.

C-clamps may be driven over the edge flanges of the flask and also the casting bottom and the lower flange of the flask to lock all the parts together. This looks the stripping plate on the flask down over the rim or edge on the core bar base so thatall of the parts are securely and positively positioned with the accurate certainty that the parts are properly set. It will be observed that in this new method the operations proceed in regular order without any removal of the parts after they have once been set-up, as was the old practice. Furthermore, the parts are securely locked together so that it is possible to utilize this present set-up for casting on moving platforms or buggies or cars which may be very desirable, but which could not be performed by a set up under the old practice. I

Having generally described the invention, it may be stated that the principal object is to provide an improvement in the art whereby the flask and core bar are interlocked in such manner as to maintain accuracy of set up without sacrifice in economy of time or labor to secure the desired result.

Another object of the present invention is that improvement in the'art whereby the flask and core bar are automatically interlocked through theagency of the casting base, which forms a third member cooperating with the flask. and core bar to fasten these parts in.

Another object of the present invention is that improvement in the art which eliminates intermediate steps heretofore practiced and to interlock through the agency of the casting base, which forms a third member cooperating with the flask and core bar to fasten these parts in.

Other and further objects of the present invention will in art be obvious and will in part be pointed out hereinafter by reference to the accompanying drawings, throughout which like parts are designated by like characters.

It is recognized that the present invention may be embodied in constructions and practiced by steps other than those herewith specifically disclosed; therefore, it is desired that the disclosure herewith shall be considered as illustrative and not in the limiting sense.

Figure 1 is "a cross section througha setu ready for casting; 3

Figure 2 is a cross-section through the flask on the pattern and ramming base;

Figure 3, is an elevation of the pattern and ramming base together;

b Figure 4 is a plan view of the pattern and ase' Figure 5 is a cross-section on line 55 of Figure 2; l

Figure 6 is a cross-section through core bar in position in the ramming box;

Figure is a plan view of the base of a core bar ramming box;

Figure 8 is a cross-section of the ramming box taken adjacent the base thereof;

Figure 9 is an elevationalview of a core bar before being rammed;

Figure 10 is a detail view of'a portion of the base of a core bar where the basecomprises a chill flange for chilling the bottom of ingot molds cast in the set-up; 4 Figure 11 is a plan View of the casting bottom; and

Figure 12 illustrates asetting pin.

Referring now more specially to the drawingjs, which illustrate a preferred embodiment of one form of device for carrying out' the present invention, the mold pattern 1 is preferably metallic and may be formed of cast iron, and is securely attached to a ramming base 2 so that the relation of the pattern to the base is fixed. Where desired, sandclearance buttons 4: having machined shallow heads may be provided on the ramming base so that these heads form the support for the flaskand provide smallsurfaces Y which maybe easily cleaned. to obviate any irregularities which might occur by particles of sand caught between the ramming base and the bottom of the flask The flask 5 is a cast iron member preferably formed in two sections (see Fig. 5) having longitudinal ribs 6 and circumferential "ribs 7 with i Y the bottom rib forming the bottom flange 8.-

A stripping-plated)v isalso formed of two sections which part where the flask sections 'part,-and these sections are secured to the bottom flange 8 of the flaskasections. The stripping plate 9 is provided with an opening which exactlyfits the base, of the mold pattern 1 sothat when the. ask is fastened together by C-elamps and is set down over the moldpattern, the' stripping plate automatically centers the flask over the pattern and the parts are accurately supported on the clearance buttons 4. This position is illustrated in Figure 2 of thedrawings, and shows the parts positioned and thesand rammed in with the gate stick 10 in position-to form the vertical portion of the-gate,

The core bar comprises a pedestal 11, which may carry theimovable collapsible sides 12, as is common in the 'art. The pedestal 11 tom of the depressed portion in order to provide supporting members for sand which may be filled in over the dished portion. The base 14 is provided with'short lugs or legs 18 on which the core bar may stand when not in use. The sides of the bottom of the core bar have machined ribs 19 thereon which are downwardly and inwardly inclined. The base 20 of the core bar ramming box is provided with 'a depression\21 which also has machined ribs 22 which have machined surfaces inclined exactly tocorrespond to the inclination of the surface on the ma'chine ribs 19 on the base l iof the core bar. Preferably sand openings are provided in the bottom between the machined ribs 22 to permit any sand which works between the ramming base and the core bar base to filter through and get out of the way. The upper face of the ramming base is provided with machinedfcurved tracks 25 that form supports for the bottom flanges of the core box sections 26 and 27. These sections are hinged. at 28 so that after the core bar base 14 is set in the depression 21 in base 20 of the core box, thereby accurately positioning the core bar in the box, these cast core box sections 26 and 27 may be swung closed to surround the core bar. Beforethe sections are closed, however, sand is rammed over the dish-shaped portion of the core bar base so as to form a rammed sandsurface extending outwardly from the base of the pedestal core bar. After the sections ofthe core box are closed and ,clamped together, the sand is rammed around the core bar as illustrated in Figure 6. i vAfter the core ibar and the sanded flask are properly black-dried, and ready for use, the core bar is set in adepression 29 in a casting bottom 30, which depression is likewise 'provided with machined supporting surfaces or ribs 31. These surfaces contact with the similar surfaces 19 on the core bar base andaccurately position the core bar relati'velyto ,the casting bottom. The

flask is thenset down over the core-bar and onto the casting bottom. Then this happensthe stripping plate 9 on the bottom of the'flask extends over the rim 16 011 the core'bar base 14 and securely locks the core I bar inflpositionp the base 'has'not been I accurately set, the weight of the. flask is fixedly mounted upon a heavy base 14 gether so that the set-up is Very secure'and rigid and is not disturbed by vibration which may be caused by movmg cars or conveyors on which this mold set-up may be placed if desired. Preferably the inner edge of the stripping plate 9 is beveled, as at 34, inorder to provide substantially a complete sand surface for the entire matrix in which the ingot mold is to be cast.

This construction presents such accurate and rigid fittings that there is little danger of any fins being formed on the bottom of the cast mold, but it will be observed that immediately back of the bottom edge of the matrix the seam or joint is formed between the cold metal rim 16 in the base 14: and the cold metal stripping plate 9 on the bottom of the flask, and consequently is a cold metal to metal joint. Therefore, if any of the hot iron should tend to leak into this joint, it is immediately chilled as soon as it strikes the cold metal to metal contact and will not proceed beyond this point.

There may be conditions where it is desired to utilize a chill at the bottom of the mold, and where this is desired, the base 14 of the core bar is not cut away to form a disk shaped member, but is left full and solid, as is indicated at on Figure 10.

In the set-up of the device, setting pins 36 or the like, may be used and preferably these pins have a conical end 37 and a rightangle turned handle 38.

adapted to go through openings in the bottom flange of the flask and cooperate with openings in the ramming plate on the pattern support and also with openings in the casting bottom in which the core bar sets.

From the foregoing it will be observed that the parts are so constructed and intel-fitted as to automatically center and interlock, thereby obviating the necessity for hand setting and also obviating inaccuracies which are necessarily attendant with hand set-ups. By means of the present construction standardized core bar bases and casting bases may be utilized with different sized ingot mold flasks ,so that a relatively few number of casting bottoms may be used with several different sizes of flasks. This isof importance because the casting bottoms can be laid'out on the casting floor or set upon cars or conveyors without requiring frequent changing. The other parts comprising the flask and core bars, are lifted to and from these bases during the-set-up and stripping operations and the bases are changed, only when widely different molds are to be cast, thereby economiz'ing in time and crane movements.

I claim is: v

1. In a mold for casting ingot molds, the combination of a flask having a sand matrix therein, a core bar having a sand facing, a core bar base rigidly secured to the core These pins are bar and having portions engaged by said flask to maintain said core bar in position, said core bar base comprising a cupped portion .carrying a sand facing, and means to support said flask and core bar base.

2. In a mold for casting ingot molds, the combination of a flask having a sand matrix therein, a core bar having a sand facing, and means comprising a core bar base rigidly secured .to the core bar and having portions extending beneath said flask to maintain said core bar in position.

3. In a mold for casting ingot molds, the combination of a flask having a sand matrix therein, a core bar having a sand facing, a core bar base rigidly secured to the core bar and having portions engaged by said flask to maintain said core bar in proper vertical alignment when the assembly is completed; and means to support said flask and core bar base.

4. In a mold for casting ingot molds, the combination of a metal flask having a sand matrix therein, a core bar having a sand facing, a core bar base rigidly secured to the core bar and having portions extending beneath said flask to permit the Weight of the flask to maintain said core bar in proper vertical alignment when the assembly is completed.

5. In a mold for casting ingot molds, the combination of a flask having a sand matrix therein, a core bar having a sand facing, a core bar base having a sand faced top and being rigidly secured to the core bar and having portions engaged by said flask to maintain said core'bar in proper vertical alignment, and means engaging said flask and said core bar base to correctly position said core bar within said flask.

6. In a mold for casting ingot molds, the combination of a flask, a casting bottom having' a seat therein extending partially under said flask, and a core bar having a base rigidly attached thereto and adapted to fit in said seat and with its, outer edge extending under said flask whereby said core bar is positively maintained in vertical alignment and in a central position with respect to said flask.

7.. In a mold for casting ingot molds, the combination of a flask havin a sand matrix therein, a casting bottom having a seat therein extending partially under and centrally positioned with'respect to said flask, and a core bar having a sand facing and having a base rigidly attached thereto and adapted to flt in said seat with its outer edge extending under said flask whereby said core bar is positively maintained in vertical alignment Havin thus CleSCI'lbOd lIly lnVOlltlOn What and in a central flask.

8. In a mold for casting ingot molds, the combination of a flask, a casting bottom adapted to support said flask and having. a seat therein, a core bar having a base rigidly position with respectto said attached thereto and having a recess carrying mold sand, said base being adapted to fit in said seat, and a stripping plate adapted adapted to be secured to said flask and hav-' ing a seat therein, a core bar having a base rigidly attached thereto and adapted to fit in said seat, to position said core with respect to said flask and a stripping plate adapted to fit between said flask and saidcasting bot,-

tom and to extend over a port-ion of said core base whereby the weight of said flask maintains said core bar in vertical position.

10. In a mold forcasting ingot molds, the combination of a metal flask having a peripheral flange on its lowerend, a stripping plate secured to said flange, acasting bottom having a seat therein, said casting bottom being adapted to be secured in a predetermined position to said flange and plate, and a core bar having a base adapted to fit in said seat and extend unde'r said plate to. maintain said core bar in a predetermined vertical position with respect to said flask.

1. In a mold for. casting ingot molds, the combination'of a flask having a peripheral flange on its lower end, astripping plate permanently secured to saidflange and extending interiorly of said flask to support a sand. matrix, a casting bottom having a seat therein, said casting bottom being adapted to be secured in a predetermined position to said flange and late, and a core bar having a base adapted to fit in said seat, the peripheral edges of saidbasebeing raised and being adapted to extend under said plate to maintain said core bar in apredetermined vertical position with respect to said flask.

12. In a mold for casting ingot molds,- the combinationof, a flask having a peripheral I flange on its lower end,,astripping plate secured tr said flange," and extending interiorly of said flask to support a sand-matrix,

the internal :edge of said plate being beveled to present a surface of mold sand-to the molten metal, a casting bottom having'a seat. therein, said casting bottom being adapted I to be secured in a predetermined position to said flange and plateand a core having a base adapted to fit in said seat and extend under said plate to maintain said core bar in a predetermined verticalposition with respect to said flask. i.

13. In a mold for casting ingot molds, the

combination of a flaskhaving a'peripheral' flange thereon, a stripping pIatesecured to said flange, a core-bar, a core bar base plate bolted to said core bar, a casting bottom having a seat therein and adapted to receive said core bar base plate, and means for securing flange thereon, a stripping plate secured to said flange and extending inwardly thereof,

.a core bar, a core barbase plate bolted to said core bar, a casting bottom having a seat therein adapted to receive said core bar base plate, and holding clamps for securing said flask base to said flask and a stripping plate attached to said flange and in engagement with the outer periphery of said core bar cal position by'tlie weight of said flask.

base plate to maintain said core bar in ve'rti- 15. In a mold for casting ingot molds, the

combination-of a flask having a sand matrix therein, a core bar having a sand facing, a

casting bottom, and a core bar base permanently moored to the core bar and hav- 111g portions extending under said flask whereby the weight of the flask holds the core bar vertical when the assembly is com pleted.'

16. In a mold for casting ingot molds, the combination of a metal flask having a sand matrix therein, a casting bottom, a core bar securely held against movement on the casting bottom, and means supporting said core barand held between the bottom and said 17. In a mold for casting ingot molds, the eombination of a flask, and a stripping plate adapted to be attached to said flask and extending interiorly thereof to support a sand matrix therein, the interior edge of said stripping plate being beveled to minimize the surface contact of the stripping plate with molten metal. A 7

18. In a mold for casting ingot molds, the combination of a core bar, a core bar base plate of greater diameter than said core bar, andmea'nsfo'r securing the base plate to the core bar, said base plate beingrecessed to receive and hold mold sand to prevent con-' tact of molten metal with said base plate.

' 19. In a mold for casting ingot molds the plate of greater diameter than said core bar,

and means for securing said base plate to said core bar, said baseplate being recessed and having raised portionsin said recess to receive and hold sand" toprevent contact; of molten metal with said base plate.

20. In a mold for. casting ingot molds,'the

than the core bar secured to said flange, ,said base plate being adapted to receivea layer of molding sand to prevent contact of molten metal" with said base plate.

combination ofv a corebar, a core bar base 21. In a mold for casting ingot molds, the combination of a core bar having a flange on the periphery of its lower end and a core bar base plate secured to said flange, said base plate being recessed in the vicinity of said flange to receive a layer of molding sand to prevent contact of molten metal with said base plate and projections in said recess to furnish an effective holding surface for said mold sand.

22. In a device of the class described the combination of a mold pattern adapted to fit into a flask to permit mold sand to be rammed therebetween, a ramming base rigidly attached to said mold pattern and clearance buttons on said base adapted to support the flask and thereby obviate any irregularities in the position of the flask caused by particles of sand caught between it and the ramming base.

23. The method of preparing a set up for casting ingot molds, which method comprises accurately securing a mold pattern within an empty flask and ramming sand between the flask and the pattern, accurately securing a core bar within a core box and ramming sand around the core bar, securely mounting the base of said core bar on a casting bottom and mounting the flask partially on said casting bottom and partially on said core bar base to rigidly and accurately hold said core bar in a predetermined position.

24. The method of preparing a set up for casting ingot molds, which method comprises automatically centering a metal mold pattern within an empty metal flask and ram ming sand between the flask and the pattern, supporting the bottom layer of the flask sand at all times, automatically centering a core bar within a core box and ramming sand around the core bar, supporting the bottom portion of the core bar sand at all times, automatically centering the base of said core bar on a casting bottom and mounting the flask partially on said casting bottom and partially on said core bar base to permit the weight of the flask to rigidly hold said core bar centered in the matrix in the flask.

25. In combination a metal flask having stripping plates attached to the bottom thereof, said stripping plates having an 'o enin therein adapted to fita pattern, a

metal pattern extending through and fitting flask and automatically centering the pat-4 tern within the flask, ramming sand between the flask and the pattern, ramming sand on the base of a core bar to form a horizontal sand face, placing the core bar within a core box and automatically centering the core bar within the core box, and ramming sand around the core bar, and mounting said rammed flask about said rammed core bar, and automatically centering the rammed flask and rammed core bar.

27. The method of preparing a set up for casting ingot molds, which method comprises placing a mold pattern within an empty flask and ramming sand between the flask and thepattern, ramming sand on the base of a core bar, placing the core bar within a core box and ramming sand around the core bar, and mounting said flask in a predetermined position about said core bar base whereby the weight of said flask maintains saidcore bar in a predetermined vertical position.

28. A set-up for casting ingot molds comprising, a flask carrying a sand mold wall facing, and a core bar having a base portion carrying a horizontal sand facing extending substantially to the sand facing on the flask.

29. A set-up for casting ingot molds comprising, a flask, a core bar, a core base permanently secured to the core bar and extending outwardly beneath the said flask, and a continuous sand facing covering the exposed horizontal portion of said core bar base and extending up the core bar to the full vertical height of the matrix of the set-up.

30. A set-up for casting ingot molds comprising, a flask, a core bar, a base on said core bar having downwardly inclined sides,

ribs on the inclined sides of said base, and a supporting stool provided with a recess to receive said base, said stool having ribs on the side walls of said recess to cooperate with the ribs on said core bar base to accurately position said core bar base in said stool.

JOHN E. PERRY. 

